Precast concrete unit system for wall construction



W. KENAN April 20, 1937.

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PRECAST CONCRETE UNIT SYSTEM FOR WALL CONSTRUCTION Filed Feb. 8, 1955 6 Sheets-Sheet 6 x/aer K nan kFrJPAkV Patented Apr. 20, 1937 UNITED STATES PATENT OFFICE PREOAST CONCRETE UNIT SYSTEM FOR WALL CONSTRUCTION 9Claims.

The object of this invention is to provide a hollow wall structure having a continuous air space and at the same time combining in such a wall structure the essential elements whereby its capacity for sustaining loads to be placed upon it is in no way minimized.

A further object of the invention is to provide a hollow masonry wall of required strength and fire-proofness which is composed of a multiplicity of precast units of standarized form and construction whereby buildings of diiferent design and formation may be erected conveniently, economically and with the aid of unskilled labor and at the same time the buildings so constructed or erected will be of maximum strength and contain other standard characteristics required in such premises.

A further object of the invention is to construct eachof the individual units in such a manner as to take full advantage of the strength of the concrete of which they are cast and at the same time pr vide these units in such form that when utilized in the erection of walls they will result in the formation of a desirable assembly having smooth outer surfaces so that any desired finish may be adopted.

Another object of the invention is to provide the units of the assembly with sealing means in their adjacent faces and also provide these same adjacent faces with enlarged contacting surfaces to increase the eifectiveness of the sealing action.

A further object resides in combining reinforcing elements and locking means, i. e., so construct the locking element or ties that they a provide the concrete units with desirable reinforcement at advantageous points in the construction.

A further object of the invention is to provide a form of tie or connection between the structural elements of the simplest form whereby quick assembly is facilitated and at the same time so arrange the locking portions of the ties that upon completion of the structure they form with the blocks substantially an integral mass.

Other objects will be obvious to one skilled in the art by an examination of the following specification, claimsand annexed drawings.

Reference will be had to the accompanying drawings forming part of this application and wherein like characters of reference designate corresponding parts throughout the several views, in which Figure 1 is a perspective view showing the 5 panel element.

Fig. 2 is a similar view of the combined reinforcing and locking element.

Fig. 3 is an elevation of one side of the panel.

Fig. 4 is a front elevation of the panel.

Fig. 5 is an elevation of the side of the panel opposite to that illustrated in Figure 3.

Fig. 6 is an end elevation.

Fig. 7 is a transverse section on line |-I of Figure 4.

Fig. 8 is a longitudinal section on line 0-8 of Figure 4.

Fig. 9 is a perspective view of the outer corner element.

Fig. 10 is a similar view of the inner corner element.

Fig. 11 is a transverse section on line H-ll of Figure 9. I

Fig. 12 is a transverse section on line l2--l2 of Figure 10.

Fig. 13 is a plan view of the combined reinforcing and locking element utilized in connection with the outer corner element of Figure 9.

Fig. 14 is a similar view of the combined reinforcing and locking element utilized in the inner corner element of Figure 10.

Fig. 15 is a transverse section through the corner elements showing the relative position of parts when assembled.

Fig. 16 is a perspective of the wall filling unit.

Fig. 1'? is a similar view of the wall tie-in unit.

Fig. 18 is a transverse section on line I 8-i8 of Figure 16.

Fig. 19 is a transverse section on line lB-lfl of Figure 17.

Fig. 20 shows a perspective of the combined reinforcing and fastening element utilized in the wall filling unit of Figure 16.

Fig. 21 is a perspective of the combinedreinforcing and securing assembly utilized in the wall tie-in unit shown in Figure 17.

Fig. 22 is a transverse section through the wall filling and wall tie-in units with these parts arranged in relative position.

Fig. 23 shows a perspective of a door jamb.

Fig. 24 is a perspective of a form of door lamb including a modified type of reinforcing and fastening element.

Fig. 25 is a perspective of a window jamb unit.

Fig. 26 is a similar view of a window jamb unit with a modified form of reinforcing element and fastener.

Fig. 2''! is a transverse section on line 21-21 of Figure 23.

Fig. 28 is a transverse sectnm on line 2l2l 01 Figure 24.

i Fig. 29 shows in perspective thewqn bined reinforcing' element and fastener utilized in the window lamb unit shown in Figure ,25.

Fig. 30 is a plan view of the combined reinforcing element and. fastener utilized 'in the window lamb unit-shown in Figure 26.

Fig. 31 is a sideelevation of a window sill unit. Fig. 32 is an end elevation of the window sill unit. Fig. -33 is a transverse section along line 33-43 ofFigure31.

Fig. 34 is a top plan view of the window sill unit.

Fig. 35 is a side elevation of the window or door head .iamb unit.

Fig. 36 is an end view of same.

Fig. 37 is a transverse section onthe line 31-31 of Figure 36.

Fig. 44 shows in perspective a wall assembly embodying some of the various elements of the invention.

The invention comprehends the utilization of a plurality of units, substantially all of which include certain common features of construction which coact and cooperate in an assembly to produce a wall structure of varying design and use. Perhaps the main element involved in the present comprehension is shown in Figures 1 to 8 and is in the form of an elongated slab. These slabs in actual use are of such a length as to provide for the height of the average wall, 1. e., the distance between the top of the supporting concrete beam below, to the bottom of the tie beam above. This distance commonly termed the wall height is in practice substantially standardized. As shown in Figures '7 and 8, each slab 2 is provided along its marginal edge with a rib 3 and imbedded in, this rib is areinforcing element 4 of desirable design. The marginal rib 3 projects a sufiicient distance to accommodate the peripheral groove l0 hereinafter more fully described. The reinforcing element 4 in the vertical ribs terminate flush with the outer surface of the block. The reinforcing element 6 which extends midway through the horizontal ribs also functions as a tie or binding 0 element as will more clearly hereinafter be described. In addition to the ribsformed along the edge of the slab there is also shown the central rib I positioned midway of the slab structure and connecting the two vertical ribs. The reinforcing element 6 in this midrib is as in the instance of the reinforcing element of the top and bottom rib also in the nature of a tie rod. The inner faces of the marginal ribs 3 and both faces of the central rib are inclined or tapered 0 throughout the entire depth of the wall as shown more clearly in Figures 4 and 8. Substantially midway in the outer face of the side and top and bottom ribs there is formed a groove Ill shown to be in semi-circular cross-section and of sufilcient 75 size to permit the accommodation 1' the en a ged head or hook of the tie rods. These grooves in each block will be formed in substantially the incorporating substantially the same structural details including an elongated angular body of uniform thickness provided about its edge with the continuous groove III in which are positioned the securing elements. These securing elements ll extend transversely through each of the angular slab bodies and terminate at opposite extremities in eyes or loops l5 which are positioned substantially half way within the groove In. These reinforcing elements are in each instance shown as being positioned one near both the top' and bottom and one approximately midway of the structures. In Figure 15 the relative position of thge corner elements in assembly is illustrated in se tion and-from this view it will be seen that the adjacent inner wall faces I! are substantially parallel thereby forming with the cooperating block or slab elements of Figures 1 to 8 inclusive a continuous wall space. It is to be noted that these corner elements each are substantially the same thickness throughout their structure which is identical to the width of the adjacent contacting faces of the ribs of theslabs shown in Figures 1 to 9 inclusive. The continuous grooves formed in these corner elements are also of identical measurement with the grooves in the slabs so that in assembling the grooves will accurately register. In Figures 13 and 14 the combined reinforcing elements and fastener is shown. In Figure 13 the reinforcing element for the outer corner element is shown and in Figure 14 the reinforcing fastening element for the inner corner element is illustrated. It will be noted that these elements are substantially identical except for length.

In Figures 16 and 18, there is illustrated an intersecting wall filling unit I8 in the form of an elongated slab of constantthickness and about the marginal edge there is formed the continuous groove I0 designed to register with the grooves of the other elements of the assembly. This filling unit is provided with the upper, lower and intermediate reinforcing rods l9, shown in Figure 20, which terminate with the hooks 20 and eyes 2| at opposite ends and which latter are positioned in the grooves III as in the preceding units described. Vertical reinforcing rods 22 are spaced longitudinally of the unit Hi to increase the strength of the structure.

In Figures 1'7, 19 and 21 there is illustrated an intersecting wall tie-in unit, substantially identical with the filling unit of Figures 16 and 18 except that the marginal grooves 10 are formed I 6' of substantially the same dimensions as the grooves in the longitudinal edges of the filling unit of Figures 16 and 18 and the other blocks and slabs heretofore described.

Figure 19 shows a transverse section which .illustrates the sectional shape and detail of the intersecting tie-in unit reinforcement and fastener. This reinforcement and fastener (see also Figure 21) includes a pair of spaced steel bars 24 arranged parallel and designed to extend vertically as regards the wall tying unit of Figure 17. Cooperating with the vertical bars 24 is a U-shaped steel locking and reinforcing tie unit which includes the central portion 25 and the leg elements 23 which latter terminate in eyes 21. It' will be noted that the vertical bars 24 are positioned within and at the junction of the legs and the body member of the U-shaped structure. Immediately below the legs of the U-shaped element is the locking steel 28 which terminates at one end in a hook 29 and at the other end in an eye 30. The dimension of these elements forming this assembly are such that when incorporated at spaced intervals in the intersecting wall tie unit the eyes 21 forming the extremities of the U-shaped member will be seated properly within the longitudinal grooves I0 formed in one of the faces of the block while the hook 29 of the steel and the eye 30 forming the other extremity of this element will be properly positioned in the grooves l0 formed in the longitudinal edges. These reinforcing and locking assemblies are positioned as in other instances immediately adjacent each end and midway of the block or slab. In Figure 22 there is illustrated in transverse section the relative position of the intersecting wall filling unit and the intersecting wall tie-in unit. The relative position of these parts is further illustrated in Figures 39 and 40 hereinafter described.

In Figure 23 there is illustrated a typical door jamb of the present system. This unit includes an elongated slab 3| cast or molded with parallel longitudinally extending grooves III in one of its side faces. The unit locking steel utilized in this door jamb is shown in Figure 29 and includes the parallel spaced elongated steel elements 32 which are positioned within the U- shaped element. This element includes a substantially straight intermediate or body portion 33 and right angle leg portions 34 which latter terminate in right angle hook extremities 35. It will be noted that the parallel reinforcing elements 32 are positioned at the junction of the body or intermediate portion 33 of the element and the legs 34. Each of the jambs 3| ilustrated in the Figure 23 are provided with two of these unit locking steels, one at approximately the lower end of the structure and the other immediately above the central portion. The right angle hook extremities of the U- shaped elements are positioned within the grooves in the face of the door lamb unit. In Figure 24 there is illustrated a door jamb unit 36 which is substantially identical in every respect with the door jamb unit of Figure 23 except for the shape of its unit locking steel, and which latter is illustrated in Figure 30 and constitutes a U-shaped structure 31 the extremities of which are formed with eyes 38 which protrude into the grooves Ill formed inthe face of the sill.

Figures 25 and 26 illustrate window jamb units both of which are identical in construction and include substantially the same general outline as the door jamb units of Figures 23 and 24 respectively. As in these latter figures, the respective window jambs of Figures 25 and 26 utilize the locking steels described in Figures 29 and 30. In regard to the window lamb units it will be noted that in place of the two unit locking steels of the door lamb only one of these elements is utilized and these at points substantially midway of the assembly. Figure 25 shows the window jamb unit with. the unitlocking steel of Figure 29, while Figure 26 shows the window jamb unit with the unit locking steel of Figure 30. In Figures 27 and 28 there are shown transverse sections with the unit locking steels in dotted position and also illustrating longitudinal reinforcing elements 40.

Figures 31, 32, 33 and 34 illustrate a window sill unit. As obvious from these views this window sill unit includes an elongated body ll having reduced extremities 42, an outwardly inclined upper face 43 stepped slightly at a point 44 beyond its longitudinal center. This window sill unit is provided in the extremities of its reduced end portions with vertical spaced grooves l0" which cooperate with similar grooves in adjoining structural elements.

Figures 35, 36, 37 and 38 represent a window or doorhead jamb unit which includes an elongated body 45 provided with reduced extremities 46 and formed midway in its upper longitudinal face with a water stop projection 41. The ends of this window or door lamb unit are provided with spaced vertical grooves III' as in the instance of the window jamb units for cooperation with adjoining elements. The window jamb units and the window or door head jamb units are provided with spaced longitudinally extending steel rods or wires 48 for reinforcing purposes. The position and distribution of these reinforcing elements may be changed to suit requirements.

Figure 39 is a horizontal section of a portion of an asembled wall in which a number of the various units of the present system have been incorporated for the purpose of fully illustrating the thoughts involved. This sectional view also includes a single and double window opening; the elongated slabs shown in Figures 1 to 8 inclusive, and the corner forming unit shown in Figures 9 to 15 inclusive. In this Figure 39 the slab illustrated in Figures 1 to 8 are indicated by reference character 2, the comer exterior unit by reference character II and the corner interior unit by reference character l2. Reference character 4| indicates the window sill units. It will be noted that in this assembly there'is provided a continuous air space and that the wall so formed. has a continuous plain or flat exterior and interior surface for the application of the desired exterior and interior wall finish thereon. This plain or flat exterior or interior surface permits the application of a finishing material without the utilization of metal laths.

In Figure 39 there is also illustrated the utilization of the various locking steels which are provided in each unit and which cooperate to permit the quick assembly of the parts.

In Figure 40 a horizontal section of an assembled wall is illustrated in-which a number of the various units of the system have been incorporated in such a manner as to illustrate their application and use. Among the elements included in the horizontal section of Figure 40 and not included in the disclosure of Figure 39 are the intersecting wall filling units illustrated in detail-in Figures 16, i8, 20 and 22. and the intersecting wall tie-in unit illustrated in detail in Figures 17, 19, 20 and 21. In addition to the foregoing there is illustrated the formation of a cross or two-way wall intersection in which the utilization of two intersecting wall tie-in units shown in detail by Figures 1'7, 19, 20, 21 and 22. In each of these illustrations the relationship of the units is clearly illustrated. 5 Figure 41 portrays the most customarily used form of the transverse and horizontal wall tie 50. Figure 42 shows in elevation an alternate design for such ties for use in cases of walls of extreme thickness, a section 43- of which is shown by Figure 43; in both Figures 42 and 43, 5| indicates the transverse tie proper which is exact in every respect with that of Figure 41 except for greater length of the round steel rod, or bar. A structural steel angle 52 is fixed to the interior angle and against and to the fillet of which the wall tie rod 5| is properly positioned and afflxed thereto securely by weldingythe transverse and horizontal wall tie so formed being stiffened by the structural angle which also acts as an accurate separator forthe units of the system when in place and forming a hollow wall.

Figure 44 illustrates in perspective a typical two story wall of a residence or analogous building in which is incorporated the essential units of the present system heretofore shown and described in detail. This view illustrates particularly the arrangement of the doors and windows and the relationship existing between the structural elements such as the slabs shown in Figures 1 to 8 and the corner elements.

With reference now to the unit locking steel utilized in connection with the various elements of the assembly attention is directed to the fact that. they function not only in tying the units in spaced fixed relation but also brace the ribs of the units to materially increase their load carrying characteristics. The location of the hooks and eyes of the unit locking steels in the grooves formed in the various edges of the block units whereby they are positioned substantially central as regards two co-acting grooves to faclli-' tate the assembling of the units is essential to the success of the invention in that the ever essential element time is well compensated for and thus the desirable structure is rendered economical.

In general it will be noted that the units forming the substance of the present invention are so constructed and designed that they are always utilized vertically and never horizontally in the 50 formation of a wall and that a wall formed by these elements is a double wall which provides for a, continuous dead air space, as contra-distinguished from a semi-hollow wall. In addition the unitscare braced both apart and together 55 so that the wall has a resulting stability as it is being placed unit by unit. This eliminates the conventional requirement for outside supporting means during assembling. By the provision of the reinforcement and the arrangement 60 of the beads on the slabs an inherent strength is provided which produces great load bearing possibilities.

It will be noted further that each section of a wall formed by the elements above described, 65 the combined use of which provides a hollow construction, includes first the essential of light weight, second, fire-proof construction and third, a continuous surface for the application of the finishing material without the use of such inde- 70 pendent elements as metallic lathing. The assembly of the combined wall sections automatically brings about an inter-bracing of the parts and when during the assembling the co-related grooves are filled with a suitable mixture of rich 75 cement or analogous composition a substantial amen unitary mass is provided reinforced and braced at the essential points.

As to. the arrangement of the continuous dead air space by the present development an exceptional splendid insulation is provided against abnormal temperatures. Obviously, the sealing of the joints by the use of a cement mixture in the co-related grooves completes the effectiveness of the formation of the continuous dead air space.

Attentiomis directed particularly to the limitednumbefi of units utilized in the construction of a building with the present system. This is particularly exemplified in Figures 39, 40 and 44 in which figures, as heretoforepointed out the wall sections are illustrated.

What I claim is: I

1. A concrete panel including a relatively thin elongated body, an outer rib extending along the edge of the body having an inner inclined face and its outer face flush with the outer edge of the panel, an intermediate rib having opposite inclined faces, reinforcing elements in said ribs, a groove formed in the outer face of said outer rib, and fastening means directly connected to said reinforcing elements embedded in said panel and terminating in said groove.

2. A corner structure including an angular outer elongated body, an inner angular body adapted to be positioned between the walls of the outer elongated body, grooves formed in the innerand outer angular body, reinforcing elements in said bodies terminating in loops in said grooves, and tie rods connecting the loops positioned within said grooves.

3. A concrete structural element comprising an elongated block having spaced grooves formed therein of semi-circular cross section, U-shaped reinforcing elements embedded in said block and terminating in fastening elements positioned in said grooves and reinforcing means extending transversely of the U-shaped member and engaging the inner faces of the same.

4. A concrete block comprising an elongated body formed with grooves in its longitudinal edges, spaced grooves .formed in one of the outer faces of said block, reinforcing bars extending transversely through said block and terminating in fastening elements positioned in grooves in the edges of said block, a U-shaped element embedded in said block having its extremities formed in loops positioned in the grooves formed in the outer face, and reinforcing bars locking fastening elements in position.

- 5. A building construction including a multiplicity of spaced panels each having registering grooves, reinforcing elements in said panels terminating in fastening elements positioned within the grooves, transversely extending blocks formed with spaced grooves in one of its faces, reinforcing elements in said transverse blocks terminating in fastening elements in said grooves, the grooves in the transverse blocks being adapted to register with the grooves in the panels and the fastening elements in the transverse block being adapted to engage the fastening devices in the panels and means for locking the panels in spaced relation.

6. A hollow wall structure including spaced wall sections each formed of a plurality of panels, said panels having thickened abutting faces, registering grooves formed in the abutting faces of said panels forming elongated chambers, reinforcing elements in said panels, fastening means connected to each panel and terminating in said chambers, means for connecting the tastening elements, and means engaging the fastening means within the chambers between the panels and connecting the walls in spaced re- 5 lation.

7. A hollow wall structure including spaced wall sections each formed of a plurality of panels, said panels having thickened abutting faces formed with continuous aligned grooves adapted 10 to register to form chambers, combined reinforcing and fastening elements embedded in said panels and terminating in said grooves in interengaged relation, and means connecting the inter-engaged fastening means between said panels 15 within said chambers for spacing said wall sections.

8. A hollow wall structure comprising a pair of spaced units each formed of a multiplicity of structural elements, each of said structural 20 elements being formed with longitudinally extending grooves and end wall blocks for connecting the spaced wall elements having one of their sides formed with grooves to register with tural elements.

9. A hollow wall structure comprising a pair of spaced units each formed of a multiplicity of structural elements, each of said structuralelements being formed with longitudinally extending grooves, reinforcing elements in said wall structure comprising imbeddedrods some of" which terminate in the registering grooves and engage with adjacent reinforcing elements, and end wall blocks for connecting the spaced wall elements having one of their sides formed with grooves to register with the grooves of the structural elements, and the edges provided with longitudinally extending grooves for cooperation with radiating structural elements.

WILDER KENAN. 

